Tangential inlet cyclone separators with low solid loading Design by means of 3D fluid dynamic optimization

Purpose - The purpose of this paper is to propose an effective methodology for the industrial design of tangential inlet cyclone separators that is based on the fully three-dimensional (3D) simulation of the flow field within the cyclone coupled with an effective genetic algorithm. Design/methodology/approach - The proposed fully 3D computational fluid dynamics (CFD) model makes use of the Reynold stress model for the accurate prediction of turbulence, while the particle trajectories are simulated using the one-way coupling discrete phase, which is a model particularly effective in case of low concentration of dust. To validate the CFD model, the numerical predictions are compared with experimental data available in the scientific literature. Eight design parameters were chosen, with the two objectives being the minimization of the pressure drop and the maximization of the collection efficiency. Findings - The optimization procedure allows the determination of the Pareto Front, which represents the set of the best geometries and can be instrumental in taking an optimal decision in the presence of such a trade-off between the two conflicting objectives. The comparison among the individuals belonging to the Pareto Front with a more standard cyclone geometry shows that such a CFD global search is very effective. Practical implications - The proposed procedure is tested for specific values of the operating conditions; however, it has general validity and can be used in place of typical procedures based on empirical models or engineers' experience for the industrial design of tangential inlet cyclone separators with low solid loading. Originality/value - Such an optimization process has never been proposed before for the design of cyclone separators; it has been developed with the aim of being both highly accurate and compatible with the industrial design time.